Photovoltaic module mounting assembly

ABSTRACT

A photovoltaic module mounting assembly ( 200 ) uses a mounting device ( 74 ), mounting plate ( 110 ′), lower bracket ( 210 ), upper bracket ( 230 ), and stud ( 114 ). The mounting plate (110′) is positioned on the mounting device ( 74 ), and a leg ( 212 ) of the lower bracket ( 210 ) is positioned on the mounting plate ( 110 ′). An outside surface ( 222 ) of another leg ( 220 ) of the lower bracket ( 210 ) includes teeth ( 224 ) and engages an inside surface ( 238 ) of a leg ( 236 ) of the upper bracket ( 230 ), which also has teeth ( 240 ). The mounting plate ( 110 ′) engages a lower surface ( 63 ) of a photovoltaic module ( 58 ), an end of the leg ( 212 ) of the lower bracket ( 210 ) may engage a side surface ( 64 ) of the module ( 58 ), and a head ( 246 ) on an end of another leg ( 232 ) of the upper bracket ( 230 ) may engage an upper surface ( 65 ) of the module ( 58 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation of pending U.S. patentapplication Ser. No. 13/965,441, that is entitled “PHOTOVOLTAIC MODULEMOUNTING ASSEMBLY,” and that was filed on Aug. 13, 2013, which isnon-provisional patent application of U.S. Provisional PatentApplication Ser. No. 61/682,570, that is entitled “PHOTOVOLTAIC MODULEMOUNTING ASSEMBLY,” that was filed on Aug. 13, 2012 (expired). Priorityis claimed to each patent application set forth in this CROSS-REFERENCETO RELATED APPLICATIONS section, and the entire disclosure of each suchpatent application is hereby incorporated by reference herein.

FIELD OF THE INVENTION

The present invention generally relates to installing structures on abuilding surface and, more particularly, to an edge or end clamp thatmay be used to install a single photovoltaic module on such a buildingsurface.

BACKGROUND

Metal panels are being increasingly used to define building surfacessuch as roofs and sidewalls. One type of metal panel is a standing seampanel, where the edges of adjacent standing seam panels of the buildingsurface are interconnected in a manner that defines a standing seam.Standing seam panels are expensive compared to other metal panels, andbuilding surfaces defined by metal panels may be more costly than othertypes of building surface constructions.

It is often desirable to install various types of structures on buildingsurfaces, such as heating, air conditioning, and ventilation equipment.Installing structures on standing seam panel building surfaces in amanner that punctures the building surface at one or more locations isundesirable in a number of respects. One is simply the desire to avoidpuncturing what is a relatively expensive building surface. Another isthat puncturing a metal panel building surface can present leakage andcorrosion issues.

Photovoltaic or solar cells have existed for some time, and have beeninstalled on various building roofs. A photovoltaic cell is typicallyincorporated into a perimeter frame of an appropriate material (e.g.,aluminum) to define a photovoltaic module or solar cell module. Multiplephotovoltaic modules may be installed in one or more rows (e.g., astring) on a roofing surface to define an array.

FIG. 1 illustrates one prior art approach that has been utilized tomount a solar cell module to a standing seam. A mounting assembly 10includes a mounting device 74, a bolt 14, and a clamping member 142.Generally, the mounting device 74 includes a slot 90 that receives atleast an upper portion of a standing seam 42. A seam fastener 106 isdirected through the mounting device 74 and into the slot 90 to forciblyretain the standing seam 42 therein. This then mounts the mountingdevice 74 to the standing seam 42.

A threaded shaft 22 of the bolt 14 from the mounting assembly 10 passesthrough an unthreaded hole in a base 154 of a clamping member 142, andinto a threaded hole 98 on an upper surface 78 of the mounting device74. This then mounts the clamping member 142 to the mounting device 74.The clamping member 142 is used to interconnect a pair of differentsolar cell module frames 62 with the mounting assembly 10. In thisregard, the clamping member 142 includes a pair of clamping legs 146,where each clamping leg 146 includes an engagement section 152 that isspaced from the upper surface 78 of the mounting device 74. The bolt 14may be threaded into the mounting device 74 to engage a head 18 of thebolt with the base 154 of the clamping member 142. Increasing the degreeof threaded engagement between the bolt 14 and the mounting device 74causes the engagement sections 152 of the clamping legs 146 to engagethe corresponding solar cell module frame 62 and force the same againstthe upper surface 78 of the mounting device 74.

SUMMARY

A first aspect of the present invention is directed to a photovoltaicmodule mounting assembly that includes a mounting device, a mountingplate, a lower bracket, an upper bracket, and a threaded clamp fastener.The mounting device is attachable to a building surface, and themounting plate is positioned on the mounting device. The lower bracketincludes first and second legs. The first leg of the lower bracket ispositioned on the mounting plate, and extends from the second leg to afree end that does not extend beyond a location in a first dimensionthat coincides with an outer perimeter of the mounting plate. The secondleg of the lower bracket extends away from the first leg in a seconddimension (e.g., the first and second dimensions may be at leastgenerally orthogonal to one another). The upper bracket includes thirdand fourth legs, with the third leg of the upper bracket and the firstleg of the lower bracket being spaced from one another in the seconddimension (e.g., a vertical dimension when installed on a roofingsurface). The fourth leg of the upper bracket extends from the third leg(e.g., in the second dimension), is disposed in a different orientationthan the third leg, and engages the second leg of the lower bracket. Thethreaded clamp fastener extends through the third leg of the upperbracket, through the first leg of the lower bracket, through themounting plate, and into threaded engagement with the mounting device.The first leg of the lower bracket is located between this threadedclamp fastener and the fourth leg of the upper bracket in the firstdimension (e.g., a lateral or horizontal dimension).

A number of feature refinements and additional features are applicableto the first aspect of the present invention. These feature refinementsand additional features may be used individually or in any combination.The following discussion is applicable to the first aspect, up to thestart of the discussion of a second aspect of the present invention.

The included angle between the first and second legs of the lowerbracket may be about 90°, the included angle between the third andfourth legs of the upper bracket may be about 90°, or both. The firstleg of the lower bracket and the third leg of the upper bracket may beleast substantially parallel to one another, the second leg of the lowerbracket and the fourth leg of the upper bracket may be at leastsubstantially parallel to one another, or both.

The first leg of the lower bracket may incorporate a first hole (e.g.,lacking threads), and the third leg of the upper bracket may incorporatea second hole (e.g., lacking threads). These two holes may be offset toat least a degree in the first dimension (e.g., a horizontal or lateraldimension). Consider the case where a first reference axis extendsbetween and is perpendicular to each of the first leg of the lowerbracket and the third leg of the upper bracket. An axis extendingbetween the centers of these two holes may be non-parallel to this firstreference axis with the mounting assembly being in an assembled state orcondition.

A first mating surface of the second leg of the lower bracket mayincorporate a plurality of spaced teeth (where this first mating surfaceprojects toward the fourth leg of the upper bracket). A second matingsurface of the fourth leg of the upper bracket may incorporate aplurality of spaced teeth (where this second mating surface projectstoward the second leg of the lower bracket). The first and second matingsurfaces may be disposed in interlocking relation to restrict relativemotion between the lower bracket and the upper bracket in the seconddimension (e.g., a vertical dimension when the mounting assembly isinstalled on a roofing surface).

The upper bracket may include a head that is offset from the third legof the upper bracket in the second dimension. The head may becharacterized as being disposed at a higher elevation than the third legwhen the mounting assembly is installed on a roofing surface. The headmay be characterized as being spaced further from a reference plane(that at least generally contains the first leg of the lower bracket),compared to the third leg of the upper bracket. In any case, the upperbracket may include a transition section between the third leg of theupper bracket and the noted head. This transition section and the freeend of the first leg for the lower bracket may be at least substantiallyaligned in the second dimension (e.g., a vertical dimension when themounting assembly is installed on a roofing surface).

The head of the upper bracket may be offset from the free end of thefirst leg of the lower bracket in the first dimension. The head of theupper bracket may be positioned closer to a position in the firstdimension, that coincides with an outer perimeter of the mounting plate,than the free end of the first leg of the lower bracket. A free end ofthe head may be positioned above the mounting plate, or stated anotherway the head may be positioned in the first dimension so as to not bedisposed beyond a position in the first dimension that coincides withthe outer perimeter of the mounting plate.

A single, continuous open space may exist between the upper bracket andthe lower bracket. In one embodiment, the only portion of the mountingassembly that extends between the upper bracket and the lower bracketthrough this space is the threaded clamp fastener. A first nut may bemounted on the threaded clamp fastener, may be engaged with the thirdleg of the upper bracket, and may be positioned outside of the notedopen space. A second nut may be mounted on the threaded clamp fastener,may be engaged with the first leg of the lower bracket, and may bepositioned within the noted open space.

The mounting assembly of the first aspect may be part of a photovoltaicsystem. In this regard, a photovoltaic module may be positioned on themounting plate and may be clamped between the upper bracket and thelower bracket. In one embodiment, an edge portion of the photovoltaicmodule includes a first side surface, an upper surface, and a lowersurface. The lower surface of this edge portion of the photovoltaicmodule may be positioned on the mounting plate. The free end of thefirst leg of the lower bracket may engage the first side surface of theedge portion of the photovoltaic module (this free end of the first legmay include a lip that extends in the direction of an overlying portionof the upper bracket). The upper bracket may engage the upper surface ofthis edge portion of the photovoltaic module (e.g., an underside of theabove-noted head may engage this upper surface of the photovoltaicmodule).

A second aspect of the present invention is directed to a photovoltaicmodule mounting assembly that includes a mounting device, a lowerbracket, an upper bracket, and a threaded clamp fastener. The mountingdevice is attachable to a building surface. The lower bracket includesfirst and second legs, where the first leg of the lower bracket extendsin a first dimension from a first intersection between the first andsecond legs, where the second leg extends in a second dimension fromthis first intersection, and where the first and second dimensions areat least generally orthogonal to one another. The upper bracket includesthird and fourth legs, where the third leg of the upper bracket extendsin the first dimension from a second intersection between the third andfourth legs, where the fourth leg extends in the second dimension fromthis second intersection, and where the fourth leg of the upper bracketengages the second leg of the lower bracket. The upper bracket furtherincludes a head, where the third leg is located between the head and thefourth leg in the first dimension. The head and the third leg of theupper bracket are offset from one another in the second dimension, withthe head being spaced further from the first leg of the lower bracket,compared to the third leg of the upper bracket and measured within thesecond dimension. The threaded clamp fastener extends through the thirdleg of the upper bracket, through an open space between the third leg ofthe upper bracket and the first leg of the lower bracket, through thefirst leg of the lower bracket, and into threaded engagement with themounting device.

A third aspect of the present invention is directed to a photovoltaicmodule mounting assembly that includes a mounting device, a lowerbracket, an upper bracket, and a threaded clamp fastener. The mountingdevice is attachable to a building surface. The lower bracket includesfirst and second legs, where the first leg of the lower bracket extendsin a first dimension from a first intersection between the first andsecond legs, where the second leg extends in a second dimension fromthis first intersection, and where the first and second dimensions areat least generally orthogonal to one another. The upper bracket includesthird and fourth legs, where the third leg of the upper bracket extendsin the first dimension from a second intersection between the third andfourth legs, where the fourth leg extends in the second dimension fromthis second intersection, and where the fourth leg of the upper bracketengages the second leg of the lower bracket. The threaded clamp fastenerextends through the third leg of the upper bracket, through an openspace between the third leg of the upper bracket and the first leg ofthe lower bracket, through the first leg of the lower bracket, and intothreaded engagement with the mounting device. The second leg of thelower bracket is located between the threaded clamp fastener and thefourth leg of the upper bracket in the first dimension.

The lower bracket and upper bracket of each of the second and thirdaspects may utilize any one more of the features of the lower bracketand the upper bracket, respectively, addressed above in relation to thefirst aspect. The lower and upper brackets of each of the second andthird aspects may be used in place of the lower bracket and upperbracket, respectively, discussed above in relation to the first aspectas well.

A number of feature refinements and additional features are separatelyapplicable to each of above-noted first, second, and third aspects ofthe present invention. These feature refinements and additional featuresmay be used individually or in any combination in relation to each ofthe first, second, and third aspects as well. Any references herein to“above,” “below,” or the like are in relation to the mounting assemblybeing in an upright position. References herein to a “vertical”dimension may be that which coincides with an upright position ororientation for the mounting assembly. For instance, if the first leg ofthe lower bracket were supported on a horizontal reference surface (todispose the mounting assembly in an upright position), the “verticaldimension” would be the dimension that is orthogonal to this horizontalreference surface. In a roofing application, the pitch of the roof maydefine the baseline for what is “upright” for purposes of the mountingassembly. That is, the noted vertical dimension may be characterized asbeing the dimension that is orthogonal to the pitch of the roof in thiscase.

The mounting device may be of any appropriate size, shape,configuration, and/or type. In one embodiment, the mounting deviceincludes a slot for receiving at least part of a standing seam of aroofing surface. One or more threaded fasteners (e.g., having ablunt-nosed or rounded end) may be used to secure the mounting device toany such standing seam, for instance without penetrating the roofingsurface.

The threaded clamp fastener may be threaded into a mounting hole on anupper wall or surface of the mounting device. Any appropriate threadedclamp fastener may be utilized to activate a clamping action for themounting assembly in relation to a photovoltaic module. A threaded studas the threaded clamp fastener may include a nut whose position is fixedon the stud (e.g., for fixing the lower bracket to a mounting device).Another nut may be threaded onto such a threaded stud (e.g., fordirecting the upper bracket toward the lower bracket).

The mounting assembly described in relation to each of the first,second, and third aspects may utilize a mounting plate. This mountingplate may be positioned on an upper wall or surface of the mountingdevice, and the lower bracket may be positioned on this mounting plate.The mounting plate may be a structure having first and second oppositelydisposed and planar surfaces. However, various features may beincorporated by the mounting plate to facilitate one or more aspects ofthe installation of a photovoltaic system. For instance, the mountingplate may incorporate one or more features to facilitate thealignment/positioning of one or more photovoltaic modules relative tothe mounting assembly for/during installation when using clampingconfigurations other than the upper and lower brackets described herein.The mounting plate may incorporate one or more features to facilitatethe grounding of a photovoltaic module that is engaged/secured by thecorresponding mounting assembly. The mounting plate may incorporate oneor more wire management features. Each of these three overall/generalfeatures may be individually incorporated by the mounting plate. Any andall combinations of these three overall/general features may beincorporated by the mounting plate as well.

The mounting plate may be of any appropriate size, shape, and/orconfiguration (e.g., a circular outer perimeter; a square outerperimeter; a rectangular outer perimeter), may be formed from anyappropriate material or combination of materials (e.g., a metal or metalalloy), or both. The mounting plate may include an upper surface and anoppositely disposed lower surface, with the lower surface being incontact with the mounting bracket (e.g., its upper surface) when themounting assembly is installed on a building surface.

The upper surface of the mounting plate may include what may becharacterized as a raised structure (e.g., of a continuous or unitarynature). First and second portions on a perimeter of this raisedstructure may be characterized as first and second PV module positionalregistrants for when the mounting plate is used with clampingconfigurations other than the upper and lower brackets described herein.In one embodiment, the free end of the first leg of the lower bracket islocated in the first dimension at a position that is beyond an outerperimeter of this raised structure.

The clamp fastener may extend through a center of the noted raisedstructure on the upper surface of the mounting plate. An outer perimeterof the raised structure may be circular in a plan view. The raisedstructure may be centrally disposed relative to an outer perimeter ofthe mounting plate. An outer perimeter of the raised structure and anouter perimeter of the mounting plate may be concentric orconcentrically disposed relative to the threaded clamp fastener. Theraised structure may be characterized as annular, doughnut-shaped, ringor ring-like, or any combination thereof. In any case, the raisedstructure may be integrally formed with a remainder of the mountingplate, such that the need to separately attach the raised structure tothe mounting plate may be alleviated (e.g., the mounting plate and theraised structure may be a one-piece structure).

The upper surface of the mounting plate may include what may becharacterized as a plurality of “grounding projections.” Each suchgrounding projection may be of any appropriate size, shape,configuration, and/or type. The grounding projections may be integrallyformed with a remainder of the mounting plate, such that the need toseparately attach each grounding projection to the mounting plate isalleviated (e.g., the mounting plate and the plurality of groundingprojections may be a one-piece structure).

The various grounding projections may be of a configuration thatfacilitates establishing an electrical connection with and/or providinga grounding function for a photovoltaic module (e.g., by engaging aframe of such a photovoltaic module, and which may require that thegrounding projection(s) pierce or penetrate a surface or surface coatingof this frame). For instance, each grounding projection couldincorporate one or more edges to desirably interface with acorresponding photovoltaic module. One or more of the groundingprojections could be in the form of a tooth or a tooth-like structure.One or more of the grounding projections could be in the form of ahollow cylinder that incorporates at least one edge on a free endthereof.

The grounding projections may be characterized as providing electricalcontinuity between adjacent photovoltaic modules that are positioned ona common mounting plate (e.g., an electrical path may encompass theframe of one photovoltaic module, one or more grounding projectionsengaged therewith, an associated mounting plate, one or more additionalgrounding projections, and the frame of another photovoltaic moduleengaged by such an additional grounding projection(s)). This may bereferred to in the art as “bonding.” In any case, the groundingprojections may be used in providing a grounding function for acorresponding photovoltaic module(s). The noted electrical connectionprovided by the grounding projections may be used to electricallyconnect adjacent photovoltaic modules (e.g., those positioned on acommon mounting plate), and which may be used to provide an electricalpath to ground a string or collection of photovoltaic modules.

The plurality of grounding projections may be characterized as beingspaced about the clamp fastener. The plurality of grounding projectionsmay be equally spaced about the clamp fastener (e.g., located every 90°in the case where there are four grounding projections). In oneembodiment, each grounding projection on the upper surface of themounting plate is located further from the clamp fastener than each ofthe first and second PV module positional registrants.

Any appropriate number of grounding projections may be utilized on theupper surface of the mounting plate, and multiple grounding projectionsmay be disposed in any appropriate arrangement. One embodiment has atleast one grounding projection engaged with each photovoltaic module(e.g., its frame) that is placed on the mounting plate. It should beappreciated that a first grounding projection or a first set ofgrounding projections could engage a first photovoltaic module placed onthe mounting plate, and that a second grounding projection or a secondset of grounding projections could engage a second photovoltaic moduleplaced on the mounting plate, where the first and second groundingprojections are different ones of the plurality of groundingprojections, and where the first and second sets of groundingprojections do not include any common grounding projections.

The number and/or arrangement of the plurality of grounding projectionsmay be selected so as to alleviate the need to position the mountingplate on the mounting device in any particular orientation, and yetstill allow one or more of the grounding projections to be in contactwith each photovoltaic module positioned on the mounting plate. Considerthe case where a first reference line extends from the threaded clampfastener and remains in a fixed position relative to the mounting plate,where a second reference line extends from the clamp fastener and movesalong with the mounting plate as the mounting plate is rotated relativeto the mounting device about the clamp fastener, and where the first andsecond reference lines are contained within a common plane. The numberand/or arrangement of the plurality of grounding projections may beselected such that any angle may exist between the first and secondreference lines (including the case where there is no angle at all or a“zero angle”), and yet still allow one or more grounding projections tobe in contact with each photovoltaic module positioned on the mountingplate.

The lower surface of the mounting plate may include at least one wiringclip, including where this lower surface includes a plurality of wiringclips. Any appropriate number of wiring clips may be utilized. Multiplewiring clips may be spaced about the clamp fastener, and including inequally-spaced relation (e.g., every 90° in the case where there arefour of such wiring clips).

The wiring clips may be of any appropriate configuration that allows oneor more wires to be retained in the space between the wiring clip andthe lower surface of the mounting plate. A portion of each wiring clipmay be disposed in at least generally parallel and spaced relation tothe lower surface of the mounting plate, and this portion may include arecessed region to facilitate the retention of one or more wires,quick-connect leads, or the like therein.

Multiple wiring clips may be disposed in any appropriate arrangement onthe lower surface of the mounting plate. Although each mounting clipcould be separately attached to the mounting plate, in one embodimenteach mounting clip is integrally formed with the remainder of themounting plate (e.g., such that the mounting plate and each of itsmounting clips is a one-piece structure). Consider the case where themounting clips are “stamped” from the body of the mounting plate. Theresulting aperture in the mounting plate may also be utilized in theinstallation of photovoltaic modules. For instance, an installer maydirect a cable or zip tie through such an aperture to bundle a pluralityof wires or the like together that are located underneath the mountingassembly or in the space between an adjacent pair of PV modules.

Any feature of any other various aspects of the present invention thatis intended to be limited to a “singular” context or the like will beclearly set forth herein by terms such as “only,” “single,” “limitedto,” or the like. Merely introducing a feature in accordance withcommonly accepted antecedent basis practice does not limit thecorresponding feature to the singular (e.g., indicating that a leg of abracket includes “a hole” alone does not mean that this leg includesonly a single hole). Moreover, any failure to use phrases such as “atleast one” also does not limit the corresponding feature to the singular(e.g., indicating that a leg of a bracket includes “a hole” alone doesnot mean that this leg includes only a single mounting hole). Use of thephrase “at least generally” or the like in relation to a particularfeature encompasses the corresponding characteristic and insubstantialvariations thereof (e.g., indicating that a leg of the upper bracket anda leg of the lower bracket are at least generally parallel to on anotherencompasses the legs being parallel to one another). Finally, areference of a feature in conjunction with the phrase “in oneembodiment” does not limit the use of the feature to a singleembodiment.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a side view of a prior art mounting assembly forinterconnecting solar cell modules with a standing seam roof.

FIG. 2 is a perspective view of a plurality of solar cell modulesinstalled on a standing seam building surface using a plurality ofadjustable mounting assemblies.

FIG. 3 is a cross-sectional schematic of a representative standing seamdefined by interconnecting a pair of panels.

FIG. 4 is a top view of one of the solar cell modules illustrated inFIG. 2.

FIG. 5 is a perspective view of one of the mounting devices that isinstalled on a standing steam in FIG. 2.

FIG. 6 is an exploded, perspective view of one of the adjustablemounting assemblies from FIG. 2.

FIG. 7A is a side view of one of the adjustable mounting assemblies fromFIG. 2, and which is engaging a pair of solar cell module frames.

FIG. 7B shows the mounting assembly of FIG. 7A being used for solar cellmodule frames having a different thickness than those illustrated inFIG. 7A.

FIG. 7C is a side view of one of the adjustable mounting assemblies fromFIG. 2 that is disposed adjacent to an edge of the building surface, andwhich is engaging a single solar cell module frame.

FIG. 8A is one side-based perspective view of another embodiment of amounting assembly for photovoltaic modules.

FIG. 8B is one top-based perspective view of the mounting assembly ofFIG. 8A.

FIG. 8C is another one top-based perspective view of the mountingassembly of FIG. 8A.

FIG. 8D is a bottom-based perspective view of the mounting assembly ofFIG. 8A.

FIG. 8E is a plan view of a bottom of the mounting assembly of FIG. 8A.

FIG. 8F is another side-based perspective view of the mounting assemblyof FIG. 8A, and schematically illustrating the engagement of a pair ofphotovoltaic modules.

FIG. 9A is a plan view of one embodiment of a photovoltaic system usinga plurality of the mounting assemblies of FIGS. 8A-F, and with theclamping members being removed to illustrate a positional registrationfunction incorporated by the mounting plate of such mounting assemblies.

FIG. 9B is a plan view of a photovoltaic system using a plurality of themounting assemblies of FIG. 6, and with the clamping members beingremoved therefrom to illustrate how a misaligned mounting assembly canaffect the ability of the same to clamp onto one or more photovoltaicmodules.

FIG. 10A is a perspective view of another embodiment of a mounting platethat incorporates a discrete pair of PV module positional registrants.

FIG. 10B is a side view of the mounting plate of FIG. 10 disposed on amounting device, where the mounting plate includes a pair of mountingdevice positional registrants.

FIG. 11 is an embodiment of a photovoltaic module mounting assembly thatuses an edge or end clamp.

FIG. 12 is an end view of the upper and lower brackets for the edgeclamp of the mounting assembly of FIG. 11.

FIG. 13 is a perspective view of the upper bracket for the edge clamp ofthe mounting assembly of FIG. 11.

FIG. 14 is a side view of the lower bracket for the edge clamp of themounting assembly of FIG. 11.

FIG. 15 is a side view of the upper bracket for the edge clamp of themounting assembly of FIG. 11.

FIG. 16A is an end view of the mounting assembly of FIG. 11, adjusted toprovide a clamping pocket of a first height.

FIG. 16B is an end view of the mounting assembly of FIG. 11, adjusted toprovide a clamping pocket of a second height.

FIG. 17A is an embodiment of a photovoltaic system that uses themounting assembly of FIG. 11.

FIG. 17B is a perspective view of the photovoltaic system of FIG. 17A.

DETAILED DESCRIPTION

FIG. 2 illustrates an assembly 30 in the form of a building surface 34,a photovoltaic or solar cell array 54 defined by a plurality ofphotovoltaic modules or solar cell modules 58 (only schematically shownin FIG. 2), and a plurality of mounting assemblies 70 a, 70 b. Thebuilding surface 34 is defined by interconnecting a plurality of panels38. Although the panels 38 may be formed from any appropriate materialor combination of materials, typically they are in the form of metalpanels 38. In any case, each adjacent pair of panels 38 isinterconnected in a manner so as to define a standing seam 42 (onlyschematically shown in FIG. 2). A base 46 is disposed between theopposing edges of each panel 38 (e.g., FIG. 3). The entirety of the base46 may be flat or planar. However, one or more small structures may beformed/shaped into the base 46 of one or more panels 38 of the buildingsurface 34 to address oil canning. These structures are commonlyreferred to as crests, minor ribs, intermediate ribs, pencil ribs,striations, fluting, or flutes.

A cross-sectional schematic of one of the standing seams 42 isillustrated in FIG. 3. There it can be seen that a pair ofinterconnected panels 38 define a standing seam 42. Generally, an edgeor edge section 50 of one panel 38 is “nested” with the opposing edge oredge section 50 of the adjacent panel 38 to define a standing seam 42.Typically each the two opposing edges 50 of a given panel 38 will be ofa different configuration. That way, one edge 50 (one configuration) ofone panel 38 will be able to “nest” with one edge 50 (anotherconfiguration) of the adjacent panel 38. Various configurations may beemployed for the edges 50 of the panels 38, and which may providedifferent configurations/profiles for the corresponding standing seam42.

A more detailed view of one of the photovoltaic modules or solar cellmodules 58 from FIG. 2 is presented in FIG. 4. Each solar cell module 58includes a frame 62 that is disposed about the corresponding solar cell66. The frame 62 may be of any appropriate size, shape, configuration,and/or type, and may be formed from any appropriate material orcombination of materials. In the illustrated embodiment, the frame 62 isof a rectangular profile, and may be formed from an appropriate metal ormetal alloy (e.g., aluminum). Similarly, the photovoltaic cell or solarcell 66 may be of any appropriate size, shape, configuration and/or typeto convert light into electricity. Typically the solar cell 66 will bein the form of a substrate having a stack of a plurality of layers. Anynumber of solar cell modules 58 may be used for the solar cell array 54of FIG. 2, and multiple solar cell modules 58 may be disposed in anyappropriate arrangement.

The mounting assemblies 70 a, 70 b that are used to install the solarcell array 54 onto the building surface 34 in FIG. 2 utilize a mountingdevice 74 that may be of any appropriate size, shape, configuration,and/or type. One configuration of a mounting device that may beinstalled on a standing seam 42 is illustrated in FIG. 5 and isidentified by reference numeral 74. This mounting device 74 includes anupper surface 78 and an oppositely disposed bottom surface 86, a pair ofoppositely disposed side surfaces 82, and a pair of oppositely disposedends 94. The upper surface 78 includes a threaded hole 98, as does atleast one of the side surfaces 82, while the bottom surface 86 includesa slot 90 that extends between the two ends 94 of the mounting device74.

The slot 90 on the bottom surface 86 of the mounting device 74 includesa base 92 a and a pair of sidewalls 92 b that are spaced apart toreceive at least an end section of a standing seam 42. One or more seamfasteners 106 may be directed through a threaded hole 102 of themounting device 74 and into the slot 90 to engage the standing seam 42and secure the same against the opposing slot sidewall 92 b. A cavity ofany appropriate type may be on this opposing slot sidewall 92 b to allowthe aligned seam fastener 106 to deflect a corresponding portion of thestanding seam 42 into this cavity, although such may not be required inall instances. In any case and in one embodiment, the seam fastener 106only interfaces with an exterior surface of the standing seam 42. Forinstance, the end of the seam fastener 106 that interfaces with thestanding seam 42 may be convex, rounded, or of a blunt-nosedconfiguration to provide a desirable interface with the standing seam42.

Other mounting device configurations may be appropriate for mounting onstanding seam 42 and that may be used in place of the mounting device 74shown in FIG. 5. Various mounting device configurations are disclosed inU.S. Pat. Nos. 5,228,248; 5,483,772; 5,941,931; 5,694,721; 5,715,640;5,983,588; 6,164,033; 6,718,718; 7,100,338; and 7,013,612, and which maybe utilized by either of the mounting assemblies 70 a, 70 b.

The mounting assembly 70 a that is used in the installation of a pair ofadjacent solar cell modules 58 in FIG. 2, and that may use a mountingdevice 74, is illustrated in FIG. 6. The mounting assembly 70 a includesa mounting device 74, along with a mounting plate 110, a clamping member142, a stud 114, and a nut 128. The mounting plate 110 is disposed onthe upper surface 78 of the mounting device 74, and includes a hole oraperture 112 that allows the stud 114 to pass therethrough. The mountingplate 110 may be utilized when it may be desirable to enhance thestability of the mounting assembly 70 a, and in any case may be of anyappropriate size, shape, configuration and/or type. The surface area ofthe mounting plate 110 is at least about 5 in² in one embodiment, and isat least about 7 in² in another embodiment. It may be possible toeliminate the mounting plate 110 from the mounting assembly 70 a, forinstance when the surface area of the upper surface 78 of the mountingdevice 74 is sufficiently large.

The stud 114 provides an interface between the clamping member 142 andthe mounting device 74, and includes a first stud end 118 and anoppositely disposed second stud end 122. A nut 126 is disposed betweenthe first stud end 118 and the second stud end 122, and is fixed to thestud 114 in any appropriate manner (e.g., welded). That is, the nut 126does not move relative to the stud 114, such that the nut 126 and stud114 will move together as a single unit. In one embodiment, the nut 126is threaded onto the stud 114, and is then fixed in the desiredlocation.

A first threaded section 130 a extends from the first stud end 118toward the second stud end 122, while a second threaded section 130 bextends from the second stud end 122 toward the first stud end 118. Anunthreaded section 134 is disposed between the fixed nut 126 and thefirst threaded section 130 a in the illustrated embodiment. However, thefirst threaded section 130 a could extend all the way to the fixed nut126 (e.g., the entire stud 114 could be threaded). In one embodiment,the length of the first threaded section is at least about 1.5 inches.

The second stud end 122 may be directed through the hole 112 in themounting plate 110 if being utilized, and in any case into a threadedhole 98 of the mounting device 74. It should be appreciated that themounting device 74 could also be disposed in a horizontal orientation ona standing seam having a horizontally disposed end section versus thevertically disposed orientation of the end section of the standing seam42, and that in this case the second stud end 122 would be directed intothe threaded hole 98 on a side surface 82 of the mounting device 74(e.g., the mounting plate 110 could then be disposed on such a sidesurface 82 if desired/required). In any case, the stud 114 may betightened onto the mounting device 74 by having an appropriate toolengage the fixed nut 126 to rotate the stud 114 relative to the mountingdevice 74 and into a desired forcible engagement with the mounting plate110 or with the corresponding surface of the mounting device 74 if themounting plate 110 is not being used. In one embodiment, the fixed nut126 is located along the length of the stud 114 such that the secondstud end 122 does not extend into the slot 90 of the mounting device 74when the stud 114 is tightened onto the mounting device 74. Having thisstud end 122 extend into the slot 90 could potentially damage thestanding seam 42.

The clamping member 142 includes a base 154 that is disposed on thefixed nut 26 of the stud 114. A hole 158 extends through the base 154and is aligned with a threaded hole 98 of the mounting device 74. In theillustrated embodiment, the hole 156 in the clamping member 142 is notthreaded such that the clamping member 142 may “slide” along the stud114.

A pair of clamping legs 146 that are disposed in opposing relationextend upwardly from the base 154 in a direction that is at leastgenerally away from the mounting device 74 when the mounting assembly 70a is installed, such that the base 154 and clamping legs 146 define anat least generally U-shaped structure. Each clamping leg 146 includes anextension 150 and an engagement section 152. The engagement sections 152are disposed in a different orientation than the extensions 150, andfunction to provide a surface to engage and clamp a structure to themounting assembly 70 a. In the illustrated embodiment, the engagementsections 150 include teeth, serrations, or like to enhance the “grip” onthe structure being clamped to the mounting assembly 70 a. The clampinglegs 146 may be of any appropriate size, shape, and/or configuration forclamping a structure to the mounting assembly 70 a. Generally, a pocket160 is defined between each engagement section 152 and the underlyingmounting plate 110/mounting device 74 for receiving a structure to beclamped to the mounting assembly 70 a.

FIG. 7A illustrates one of the mounting assemblies 70 a from FIG. 2, andwhich again interfaces with a pair of solar cell modules 58.Installation of such a mounting assembly 70 a could entail directing atleast the upper portion of the standing seam 42 into the slot 90 of themounting device 74. Thereafter, the mounting device 74 may be secured tothe standing seam 42 using at least one seam fastener 106. Once again,the seam fastener 106 may be directed through the mounting device 74 andinto the slot 90 to force a corresponding portion of the standing seam42 against the opposing slot sidewall 92 b.

The mounting plate 110 may be disposed on the upper surface 78 of themounting device 74 such that its hole 112 is aligned with a threadedhole 98 on the mounting device 74 that will receive the stud 114. Thesecond stud end 122 may then be directed through the hole 112 of themounting plate 110 such that the stud 114 may be threaded to themounting device 74 (e.g., using a wrench on the fixed nut 126 to clampthe mounting plate 110 between the fixed nut 126 and the mounting device74). At this time, the lower surface of the fixed nut 126 engages theupper surface of the mounting plate 110 or a corresponding surface ofthe mounting device 74 if the mounting plate 110 is not used. Aspreviously noted, and as illustrated in FIG. 7A, in one embodiment thesecond stud end 122 does not pass into the slot 90 of the mountingdevice 74. It should be appreciated that the mounting plate 110 and stud114 could be installed on the mounting device 74 prior to itsinstallation on the standing seam 42.

A frame 62 from one of the solar cell modules 58 may be positioned onone side of the mounting plate 110, while a frame 62 from another of thesolar cell modules 58 may be positioned on the opposite side of themounting plate 110. The clamping member 142 may or may not be positionedon the stud 114 at the time the solar cell module frames 62 arepositioned on the mounting plate 110. In any case, the first stud end118 may be directed through the hole 158 on the base 154 of the clampingmember 142. At this time a portion of one solar cell module frame 62will then be positioned between the mounting plate 110 and theengagement section 152 of one of the clamping legs 146, while a portionof another solar cell module frame 62 will then be positioned betweenthe mounting plate 110 and the engagement section 152 of the otherclamping leg 146. The nut 128 may then be threaded onto the first studend 118 of the stud 114 until the engagement sections 152 of theclamping member 142 exert a desired force on the two solar cell moduleframes 62 (e.g., to clamp these frames 62 between the engagementsections 152 of the clamping member 142 and the mounting plate 110, orbetween the engagement sections 152 of the clamping member 142 and themounting device 74 if the mounting plate 110 is not being used). Thatis, turning the nut 128 may move the clamping member 142 along the stud114 and toward the mounting device 74 (e.g., by the clamping member 142“sliding” along the stud 114) to generate the desired clamping action.It should be appreciated that the clamping member 142 and possibly thenut 128 could be positioned on the stud 114 at the time when the solarcell module frames 62 are disposed on the mounting plate 110, althoughthis may require that the clamping member 142 be lifted to a degree atthis time to accommodate positioning the frames 62 under the engagementsections 152 of the clamping member 142.

As evident by a review of FIG. 7A, the stud 114 may extend beyond thenut 128 in the installed configuration. Preferably the first threadedsection 130 a of the stud 114 is of a length that allows the mountingassembly 70 a to be used to clamp structures of various thicknesses tothe mounting assembly 70 a. For instance, FIG. 7B illustrates a pair ofsolar cell module frames 62′ being clamped to the mounting assembly 70a, where these frames 62′ are thicker than the frames 62 presented inFIG. 7A. In one embodiment, the length of the first threaded section 130a is at least about 1.5 inches, and which accommodates using themounting assembly 70 a to clamp solar cell modules of a number ofdifferent thicknesses (e.g., the fixed nut 126 may be spaced from thefirst stud end 118 by a distance of at least about 1.5 inches, the firstthreaded section 130 a may extend all the way to the fixed nut 126, orboth).

The above-described mounting assemblies 70 a may be used tosimultaneously engage the frame 62 of a pair of solar cell modules 58.In at least some cases, there may only be a need to engage a singlesolar cell 58, such as in the case of those solar cells 58 that aredisposed closest to an edge 36 of the building surface 34 (FIG. 2). FIG.7C illustrates a configuration for this situation, and which isidentified by reference numeral 70 b. Corresponding parts of themounting assemblies 70 a and 70 b are identified by the same referencenumeral. The only difference between the mounting assembly 70 b and themounting assembly 70 a is that an additional nut 128 is used by themounting assembly 70 b. Therefore, the remainder of the discussionpresented above also applies to the mounting assembly 70 b.

Generally, one nut 128 is threaded onto the first stud end 118, followedby positioning a clamping member 142 over the first stud end 118 andonto the stud 114, then followed by a second nut 128 that is threadedonto the first stud end 118. The lower nut 128 may be threaded down asufficient distance on the stud 114. Thereafter, the top nut 128 may bethreaded to clamp a solar cell module frame 62″ between the mountingplate 110 and the engagement section 152 of one of the clamping members142. The lower nut 128 may then be threaded upwardly on the stud 118 toengage the underside of the base 154 of the clamping member 142.

Another embodiment of a mounting assembly, which may be used formounting photovoltaic or solar cell modules to a building surface havinga plurality of standing seams defined by a plurality of interconnectedpanels, is illustrated in FIGS. 8A-F and is identified by referencenumeral 70 c. Corresponding components between the mounting assembly 70c and the above-discussed mounting assembly 70 a are identified by thesame reference numerals. Those corresponding components between thesetwo embodiments that differ in at least some respect are identified bythe same reference numeral, but with a “single prime” designation inrelation to the mounting assembly 70 c.

The mounting assembly 70 c of FIGS. 8A-F utilizes the above-discussedmounting device 74, clamping member 142, and stud 114. All of thefeatures discussed above in relation to each of these components remainequally applicable to the mounting assembly 70 c. The mounting assembly70 c does utilize a mounting plate 110′ that is positioned on an uppersurface 78 of the mounting device 74, and that is located between theclamping member 142 and the mounting device 74 in a dimensioncorresponding with the length dimension of the stud 114. However, themounting place 110′ is of a different configuration than the mountingplate 110 utilized by the mounting assembly 70 a, and therefore thenoted “single prime” designation is utilized.

The mounting plate 110′ includes an upper surface 170 and an oppositelydisposed lower surface 176. The upper surface 170 includes a pluralityof grounding projections 172. The grounding projections 172 may beintegrally formed with a remainder of the mounting plate 110′ (e.g., themounting plate 110′ and grounding projections 172 may be of one-piececonstruction, such that the individual grounding projections 172 do notneed to be separately attached to the mounting plate 110′). Anyappropriate number of grounding projections 172 may be utilized. Eachgrounding projection 172 may be of any appropriate size, shape, and/orconfiguration. The various grounding projections 172 may be equallyspaced from the stud 114, may be equally spaced about the stud 114, orboth.

In one embodiment, the number of grounding projections 172 is selectedand the grounding projections 172 are arranged such that at least onegrounding projection 172 will engage each photovoltaic module beingmounted to a building surface by the clamp assembly 70 c, regardless ofthe angular position of the mounting plate 110′ relative to the stud114. “Angular position” does not mean that the mounting plate 110′ isdisposed at an angle relative to the upper surface 78 of the mountingdevice 74. Instead, “angular position” means a position of the mountingplate 110′ that may be realized by rotating the mounting plate 110′relative to the stud 114 and/or the mounting device 74. Consider thecase where the ends 94 of the mounting device 74 define the 12 o'clockand 6 o'clock positions. The mounting plate 110′ may be positioned onthe mounting device 74 with each of its grounding projections 172 beingdisposed at any angle relative to the 12 o'clock position (e.g., in the1 o'clock position, in the 2 o'clock position, in the 8 o'clockposition, etc), and yet at least one grounding projection 172 willengage each photovoltaic module being mounted to a building surface bythe clamp assembly 70 c. The “angle” of each such grounding projection172 is the angle between first and second reference lines that aredisposed within a common plane, the first reference line remaining in afixed position relative to the mounting plate 110′ and extending fromthe stud 114, for instance, to the noted 12 o'clock position. The secondreference line may also extend from the stud 114 to a particulargrounding projection 172, and thereby may rotate along with the mountingplate 110′ as its angular position is adjusted relative to the stud 114and/or mounting device 74.

The grounding projections 172 may facilitate establishing an electricalconnection with and/or assisting in grounding one or more photovoltaicmodules. The grounding projections 172 may be characterized as providingelectrical continuity between adjacent photovoltaic modules that arepositioned on the same mounting plate 110′ (e.g., an electrical path mayencompass the frame of one photovoltaic module, one or more groundingprojections 172 engaged therewith, the mounting plate 110′, one or moreadditional grounding projections 172, and the frame of anotherphotovoltaic module engaged by such an additional groundingprojection(s) 172). This may be referred to in the art as “bonding.” Inany case, the grounding projections 172 may be used in providing agrounding function for a corresponding photovoltaic module(s). The notedelectrical connection provided by the grounding projections 172 may beused to electrically connect adjacent photovoltaic modules (e.g., thosepositioned on a common mounting plate 110′), and which may be used toprovide an electrical path to ground a string or collection ofphotovoltaic modules.

The mounting device 110′ also includes a raised structure 174 on itsupper surface 170. The raised structure 174 may be disposed about theun-threaded hole 112 in the mounting plate 110′ and through which thestud 114 passes. Generally and as will be discussed in more detailbelow, the raised structure 174 may be used to determine where aphotovoltaic module should be positioned on the upper surface 170 of themounting plate 110′ to ensure that the clamping member 142 willadequately engage not only this photovoltaic module, but an adjacentlydisposed photovoltaic module as well. As such, the raised structure 174may be characterized as a positional registrant or alignment feature foreach an adjacent pair of photovoltaic modules being clamped by a commonmounting assembly 70 c.

The raised structure 174 may be integrally formed with a remainder ofthe mounting plate 110′ (e.g., the mounting plate 110′ and raisedstructure 174 may be of one-piece construction, such that the raisedstructure 174 does not need to be separately attached to the mountingplate 110′). The raised structure 174 may be characterized as beingdoughnut-shaped. The raised structure 174 may extend completely aboutthe stud 114, the stud 114 may extend through a center of the raisedstructure 174, or both. The raised structure 174 may be circular in aplan view. This alleviates the requirement to have the mounting plate110′ be in a certain angular position on the upper surface 78 of themounting device 74 to provide its positional registration or alignmentfunction in relation to the photovoltaic modules to be clamped. An outerperimeter of the raised structure 174 and an outer perimeter of themounting plate 110′ may be concentrically disposed relative to the stud114. The raised structure 174 may be centrally disposed relative to anouter perimeter of the mounting plate 110′.

The lower surface 176 of the mounting plate 110′ includes a plurality ofwiring tabs or clips 178. The wiring clips 178 may be integrally formedwith a remainder of the mounting plate 110′ (e.g., the mounting plate110′ and wiring clips 178 may be of one-piece construction, such thatthe individual wiring clips 178 do not need to be separately attached tothe mounting plate 110′). For instance, the wiring clips 178 could be“stamped” from the body of the mounting plate 110′. In this regard, themounting plate 110′ includes an aperture 184 for each such wiring clip178. Any appropriate number of wiring clips 178 may be utilized. Thevarious wiring clips 178 may be equally spaced from the stud 114, may beequally spaced about the stud 114, or both.

In one embodiment, the number of wiring clips 178 is selected and thewiring clips 178 are arranged such that at least one wiring clip 178should be available for holding/retaining one or more wires from/foreach photovoltaic module being mounted to a building surface by theclamp assembly 70 c, regardless of the angular position of the mountingplate 110′ relative to the stud 114 and/or mounting device 74.

Each wiring clip 178 may be of any appropriate size, shape, and/orconfiguration. In the illustrated embodiment, each wiring clip 178includes a first segment 180 a that extends away from the lower surface176 of the mounting plate 110′, along with a second segment 180 b thatextends from a distal end of the first segment 180 a. The second segment180 b may be disposed at least generally parallel with the lower surface176 of the mounting plate 110′. In any case, the second segment 180 bmay include a recessed region 182 (e.g., a concave area) to facilitateretention of one or more wires and/or quick-connect leads.

A wiring clip 178 may be used the support and/or retain thequick-connect lead(s) associated with one of the photovoltaic modulesbeing clamped by the corresponding mounting assembly 70 c (e.g., bybeing positioned within the space between the second segment 180 b of agiven wiring clip 178 and the lower surface 176 of the mounting plate110′, for instance by resting in a concave portion of the second segment180 b in the form of the noted recessed region 182). Other wires couldbe directed into the space between the second segment 180 b of a givenwiring clip 178 and the lower surface 176 of the mounting plate 110′.

Another function is indirectly provided by the wiring clips 178. Theaperture 184 associated with each wiring clip 178 provides a spacethrough which an installer may direct cable or zip tie or the like tobundle together various wires that may be located at a lower elevationthan the mounting plate 110′ (e.g., wires underneath the mountingassembly 70 c; wires underneath a photovoltaic module being clamped bythe mounting assembly 70 c; wires in a space between a pair ofphotovoltaic modules being clamped by the mounting assembly 70 c).

FIG. 8F schematically illustrates the positional registration/alignmentfunction provided by the raised structure 174 of the mounting plate110′. Here the frame 62 of one photovoltaic module 58 being clamped bythe mounting assembly 70 c abuts one portion on a perimeter of theraised structure 174, while the frame 62 of another photovoltaic module58 being clamped by the mounting assembly 70 c is disposed adjacent to(or possibly abutting with) an oppositely disposed portion on theperimeter of the raised structure 174. In one embodiment, the width orouter diameter of the raised structure 174 is the same as or slightlylarger than the spacing between the two extensions 150 of the clampingmember 142. In any case, the raised structure 174 should be sized suchthat when an adjacent pair of photovoltaic modules 58 are positioned toabut oppositely disposed portions on the perimeter of the raisedstructure 174, the clamping member 142 should be positionable on thestud 114 and should properly engage these photovoltaic modules.

At least one grounding projection 172 of the mounting plate 110′ shownin FIG. 8F should be engaged with the frame 62 of one photovoltaicmodule 58 shown in FIG. 8F, and at least one other grounding projection172 of this same mounting plate 110′ should be engaged with the frame 62of the other photovoltaic module 58 shown in FIG. 8F. This againprovides electrical continuity between the two modules 58 shown in FIG.8F—an electrical path exists from one module 58 to the other module 58via the mounting plate 110′ and each grounding projection 172 that isengaged with either of the modules 58.

FIG. 9A illustrates the positional registration or alignment functionprovided by the mounting plate 110′ incorporating a raised structure 174(which thereby may be referred to as a PV module positional registrant).In FIG. 9A, the mounting devices 74 are attached to the standing seams42 such that the frame 62 of the photovoltaic module 58 engages aportion on the outer perimeter of the raised structure 174. The clampingmember 142 for each such mounting device 74 should not only be in properposition to adequately engage the frame 62 of the photovoltaic module 58shown in FIG. 9A, but the clamping member 142 for each such mountingdevice 74 should also be in proper position to adequately engage theframe 62 of another photovoltaic module 58 that would be positioned inthe uphill direction A (e.g., the arrow A indicating the direction ofincreasing elevation) from the illustrated photovoltaic module 58. Theframe 62 of this “uphill” photovoltaic module 58 would likely engage anopposing portion of the raised structure 174 (or be disposed in closelyspaced relation thereto). Any “downward drifting” of this uphillphotovoltaic module 58 should be stopped by engaging the raisedstructure 174 of the “downhill” mounting assemblies 70 c.

Now compare FIG. 9A to FIG. 9B. In FIG. 9B, the mounting assembly 70 ahas been used, and whose mounting plate 110 does not incorporate theraised structure 174 from the mounting plate 110′ of FIGS. 8A-F. Here itcan be seen that the uphill photovoltaic module 58 a (the arrow B inFIG. 9B indicating the downhill direction, or direction of decreasingelevation) has been positioned relative to the three lower mountingdevices 74 such that its frame 62 is quite close to the hole 112 of thethree lower mounting plates 110 (through which the stud 114 is directedto threadably engage the mounting device 74). The three clamping members142 associated with these three “downhill” mounting plates 110 now maynot sufficiently engage the downhill photovoltaic module 58 b.

The mounting plate 110′ from the mounting assembly 70 c of FIGS. 8A-Fuses a single raised structure 174 to provide a positional registrationor alignment function for each of the two photovoltaic modules that maybe clamped by a single mounting assembly 70 c. Other types of positionalregistration or alignment features may be incorporated by a mountingplate. One representative embodiment is illustrated in FIGS. 10A-B inthe form of a mounting plate 110″. Generally, the mounting plate 110″may be used in place of the mounting plate 110′ discussed above.Although not shown, it should be appreciated that the mounting plate110″ may also utilize the grounding projections 172 and/or wiring clips178 (and their associated apertures 184).

The mounting plate 110″ of FIGS. 10A and 10B differs from the mountingplate 110′ of FIGS. 8A-F in a number of respects. One is the shape ofthe mounting plate 110′. Each of these mounting plates 110′, 110″ may beof any appropriate shape in relation to their respective outerperimeters (e.g., circular as in the case of the mounting plate 110;square as in the case of the mounting plate 110″; rectangular). Anotheris that the mounting plate 110″ utilizes at least two discrete PV modulepositional registrants 190. Each of the PV module positional registrants190 may be of any appropriate size, shape, and/or configuration. The PVmodule positional registrants 190 may be integrally formed with aremainder of the mounting plate 110″ as shown where they have beenstamped from the mounting plate 110″ (creating corresponding apertures192), or the PV module registrants 190 could be separately attached tothe mounting plate 110″. When the mounting plate 110″ is positioned inthe proper orientation on a mounting device 74, one of the PV modulepositional registrants 190 may be used to position one photovoltaicmodule on the mounting plate 110″ (e.g., by this first photovoltaicmodule butting up against this first PV module positional registrant190) such that it should be adequately engaged by the clamping member142, and furthermore such that the other or second photovoltaic moduleto be positioned on the mounting plate 110″ should also be adequatelyengaged by this same clamping member 142. In this regard, this secondphotovoltaic module may be positioned such that it butts up against theother or second of the PV module positional registrants 190 of themounting plate 110″.

As there are only two PV module positional registrants 190 in theillustrated embodiment of FIGS. 10A and 10B, the mounting plate 110″ mayneed to be in a certain angular position or orientation on the mountingdevice 74 such that they provide a positional registration or alignmentfunction for the two photovoltaic modules to be clamped by theassociated mounting assembly. An installer could be required to placethe mounting plate 110″ onto the mounting device 74 in the correctangular position or orientation. Another option is for the mountingplate 110″ to include one or more mounting device positional registrants194 that facilitate the positioning of the mounting plate 110″ onto theupper surface 78 of the mounting device 74 such that the PV modulepositional registrants 190 should be positioned to provide a positionalregistration or alignment function for the two photovoltaic modules tobe clamped by the associated mounting assembly. In the illustratedembodiment, the mounting plate 110″ includes a pair of mounting devicepositional registrants 194—a separate mounting device positionalregistrant 194 for each of the two opposite ends 94 of the mountingdevice 74 (e.g., one mounting device positional registrant 194 mayengage one end 94 of the mounting device 74, and another mounting devicepositional registrant 194 may engage the opposite end 94 of the mountingdevice 74). A pair of mounting device positional registrants could beutilized by the mounting plate 110″ and that engage the two oppositeside surfaces 82 of the mounting device 74 to place the mounting plate110″ in the correct angular position relative to the mounting device 74.Yet another option would be to have at least one mounting devicepositional registrant for the mounting plate 110″ that engages an end 94of the mounting device 74 and at least one mounting device positionalregistrant for the mounting plate 110″ that engages one of the sidesurfaces 82 of the mounting device 74. Any appropriate way ofpositionally registering the mounting plate 110″ relative to themounting device 74 may be utilized.

An embodiment of a photovoltaic module mounting assembly that utilizesan edge or end clamp is illustrated in FIGS. 11-15 and is identified byreference numeral 200. The mounting assembly 200 includes a mountingdevice 74, a mounting plate 110′, a threaded stud 114 (e.g., a threadedclamp fastener), and an edge or end clamp 205. As discussed, themounting device 74 may be positioned on a standing seam of a buildingsurface. Other mounting devices may be appropriate for the mountingassembly 200.

The mounting plate 110′ is positioned on an upper wall or surface 78 ofthe mounting device 74. The upper surface 170 of the mounting plate 110′includes the above-noted raised structure 174 and a plurality ofgrounding projections 172, while a plurality of the above-noted wiringclips 178 may be associated with the lower surface 176 or underside ofthe mounting plate 110′. The mounting plate 110′ extends beyond aperimeter of the upper surface 170 of the mounting device 74. Othermounting plates may be used by the mounting assembly 200, including themounting plates 110, 110″ addressed above.

The edge clamp 205 includes a lower bracket 210 and an upper bracket 230that collectively define a single, continuous pocket 252 for receivingan edge portion of a photovoltaic module. In the illustrated embodiment,the length L₁ (FIG. 14; e.g., about 2 inches) of the lower bracket 210is greater than the length L₂ (FIG. 15; e.g., about 1.5 inches) of theupper bracket 230 (see FIG. 17B discussed below, where the lower bracket210 extends beyond both ends of the upper bracket 230 in the lengthdimension). The length dimension of each of the lower bracket 210 andupper bracket 230 extends along an edge portion of a photovoltaic modulewhen engaged by the mounting assembly 200.

The lower bracket 210 includes a first leg 212 and a second leg 220 thatmeet at a first intersection 228. In one embodiment, an included anglebetween the first leg 212 and the second leg 220 is about 90°. As such,the lower bracket 210 may be referred to as an L-bracket 210. Howeverand more generally, the first leg 212 and second leg 220 may becharacterized as being disposed in different orientations.

The first leg 212 extends away from the first intersection 228. Wheninstalled on a building surface, the first leg 212 may be characterizedas extending within a horizontal or lateral dimension (e.g., a firstdimension; within a plane that is at least generally parallel with thepitch of a roofing surface on which the mounting assembly 200 isinstalled). A free end 214 of the first leg 212 is spaced from the firstintersection 228. A lip 216 extends in the direction of the overlyingportion of the upper bracket 230 at the free end 214 of the first leg212. A hole 218 is located between the first intersection 228 and thefree end 214 of the first leg 212. In one embodiment, the hole 218 isun-threaded.

The second leg 220 of the lower bracket 210 extends away from the firstintersection 228. When installed on a building surface, the second leg220 may be characterized as extending within a vertical dimension (e.g.,a second dimension; at least generally orthogonal to the pitch of aroofing surface on which the mounting assembly 200 is installed). A freeend 226 of the second leg 220 is spaced from the first intersection 228.An outside surface 222 of the second leg 220 includes a plurality ofspaced teeth 224. “Outside” in relation to surface 222 is in relation tothe pocket 252—the surface 222 is on a side of the second leg 220 thatfaces or projects away from the single, continuous pocket 252collectively defined by the lower bracket 210 and upper bracket 230.

The upper bracket 230 includes a third leg 232 and a fourth leg 236 thatmeet at a second intersection 244. In one embodiment, an included anglebetween the third leg 232 and the fourth leg 236 is about 90°. As such,the third leg 232 and the fourth leg 236 may be characterized asdefining an L-shaped section for the upper bracket 230. However and moregenerally, the third leg 232 and fourth leg 236 may be characterized asbeing disposed in different orientations. The first leg 212 of the lowerbracket 210 and the third leg 232 of the upper bracket 230 may be atleast generally parallel to one another. The second leg 220 of the lowerbracket 210 and the fourth leg 236 of the upper bracket 230 may be atleast generally parallel to one another.

The third leg 232 of the upper bracket 230 extends away from the secondintersection 244. When installed on a building surface, the third leg232 may be characterized as extending within a horizontal or lateraldimension (e.g., a first dimension; within a plane that is at leastgenerally parallel with the pitch of a roofing surface on which themounting assembly 200 is installed).

A hole 234 extends through the third leg 232 of the upper bracket 230 ata location that is spaced from the second intersection 244. In oneembodiment, the hole 234 is un-threaded. The hole 234 associated withthe upper bracket 230 and the hole 218 associated with the lower bracket210 may be mis-aligned in the vertical or second dimension—thecenterline of the hole 234 (upper bracket 230) may be slightly offsetfrom the centerline of the hole 218 (lower bracket 210) in thehorizontal or lateral dimension (e.g., a first dimension). Statedanother way, an axis extending between the centers of the holes 234, 218may not be parallel with a reference axis that extends between and thatis perpendicular to each of the first leg 212 of the lower bracket 210and the third leg 232 of the upper bracket 230.

The fourth leg 236 of the upper bracket 230 extends away from the secondintersection 244. When installed on a building surface, the fourth leg236 may be characterized as extending within a vertical dimension (e.g.,a second dimension; at least generally orthogonal to the pitch of aroofing surface on which the mounting assembly 200 is installed). A freeend 242 of the fourth leg 236 is spaced from the second intersection244. An inside surface 238 of the fourth leg 236 includes a plurality ofspaced teeth 240. “Inside” in relation to surface 238 is in relation tothe pocket 252—the surface 238 is on a side of the fourth leg 236 thatfaces or projects toward the single, continuous pocket 252 collectivelydefined by the lower bracket 210 and upper bracket 230.

The outside surface 222 of the second leg 220 (lower bracket 210) isdisposed in interfacing relation with the inside surface 238 of thefourth leg 236 (upper bracket 230). Generally, teeth 224 associated withthe second leg 220 (lower bracket 210) are disposed between teeth 240associated with the fourth leg 236 (upper bracket 230) to interlock thelower bracket 210 with the upper bracket 230 in the vertical or seconddimension (e.g., a given tooth 224 associated with the lower bracket 210is disposed between a pair of adjacent teeth 240 of the upper bracket230, and vice versa). This interlocking relation between the lowerbracket 210 and the upper bracket 230 resists/impedes relative movementbetween the upper bracket 230 and the lower bracket 210 in the verticaldimension (e.g., a second dimension). The height or thickness of thepocket 252 may be adjusted by changing the amount of interface betweenthe outside surface 222 of the second leg 220 (lower bracket 210) andthe inside surface 238 of the fourth leg 236 (upper bracket 230). Thisallows the mounting assembly 200 to be used to clamp photovoltaicmodules of different thicknesses or heights.

The upper bracket 230 also includes a head 246 that is spaced from thesecond intersection 244 (between the third leg 232 and the fourth leg236). The head 246 is offset from the third leg 232 in the verticaldimension (e.g., a second dimension). In this regard, a transitionsection 250 extends from an end of the third leg 232 to the head 246.This disposes an underside 249 of the head 246 at a higher elevationthan the third leg 232 when the mounting assembly 200 is positioned on aroofing surface. Stated another way, the underside 249 of the head 246(upper bracket 230) is spaced further from a reference plane (that atleast generally contains the first leg 212 of the lower bracket 210),compared to the third leg 232 (upper bracket 230). The underside 249 ofthe head 246 may include serrations 248 for interacting with aphotovoltaic module being clamped by the mounting assembly 200.

FIGS. 16A and 16B show the mounting assembly 200 in an assembledcondition or state. In each instance, the first stud end 118 of the stud114 is directed through the hole 234 in the third leg 232 (upper bracket230), while the second stud end 122 is directed through the hole 218 inthe first leg 212 (lower bracket 210), then through the hole 112 in themounting plate 110′, and then into the threaded hole 98 on the uppersurface or wall 78 of the mounting device 74. The stud 114 may bethreaded into the mounting device 74 to dispose the nut 126 against thefirst leg 212 of the lower bracket 210. The nut 128 may be threaded ontofirst stud end 118 and may be disposed against the third leg 232 of theupper bracket 230.

FIG. 16A shows the mounting assembly 200 having been adjusted to providea minimum clamping pocket—to provide a minimum thickness or height forthe single, continuous pocket 252 collectively defined by the lowerbracket 210 and the upper bracket 230. Here, the free end 226 of thesecond leg 220 (lower bracket 210) may be disposed against the undersideof the third leg 232 of the upper bracket 230. This provides a maximuminterface between the outside surface 222 of the second leg 220 (lowerbracket 210) and the inside surface 238 of the fourth leg 236 (upperbracket 230). Relative motion between the upper bracket 230 and thelower bracket 210 in the vertical dimension (e.g., a second dimension)is restricted by the interlocking teeth 240, 224 as noted above.

FIG. 16B shows the mounting assembly 200 having been adjusted to providea larger clamping pocket in the vertical dimension (e.g., a seconddimension) than the FIG. 16A configuration—this may provide a maximumthickness or height for the single, continuous pocket 252 collectivelydefined by the lower bracket 210 and the upper bracket 230. Here, thefree end 226 of the second leg 220 (lower bracket 210) is spaced fromthe underside of the third leg 232 of the upper bracket 230. Thisprovides a reduced interface between the outside surface 222 of thesecond leg 220 (lower bracket 210) and the inside surface 238 of thefourth leg 236 (upper bracket 230), compared to the FIG. 16Aconfiguration. However, relative motion between the upper bracket 230and the lower bracket 210 in the vertical dimension (e.g., a seconddimension) should still be restricted/impeded by the interlocking teeth240, 224. It should be appreciated that the upper bracket 230 may bedisposed at various intermediate locations between the positions ofFIGS. 16A and 16B to accommodate the thickness or height of thephotovoltaic module being engaged by the mounting assembly 200.

The only portion of the mounting assembly 200 that extends between theupper bracket 230 and the lower bracket 210 within the pocket 252 of themounting assembly 200 is the stud 114. The second leg 220 of the lowerbracket 210 may be characterized as being located between the stud 114and the fourth leg 236 of the upper bracket 230 in the lateral orhorizontal dimension (e.g., a first dimension). The free end 214 of thefirst leg 212 for the lower bracket 210 does not extend beyond alocation in the lateral or horizontal dimension (e.g., a firstdimension) that coincides with an outer perimeter of the mounting plate110′ in the illustrated embodiment. The free end 214 of the first leg212 for the lower bracket 210 does extend beyond a location in thelateral or horizontal dimension (e.g., a first dimension) that coincideswith an outer perimeter of the raised structure 174 in the illustratedembodiment. The free end 214 of the first leg 212 for the lower bracket210 is offset from the head 246 of the upper bracket 230 in the lateralor horizontal dimension (e.g., a first dimension). In the illustratedembodiment, an end 247 of the head 246 is spaced further from the stud114 than the free end 214 of the first leg 212 for the lower bracket210, measured in the lateral or horizontal dimension (e.g., a firstdimension). However, the head 246 does not protrude beyond a location inthe lateral or horizontal dimension (e.g., a first dimension) thatcoincides with the outer perimeter of the mounting plate 110′.

Having the second leg 220 of the lower bracket 210 be positioned insidethe fourth leg 236 of the upper bracket 230 provides a desiredrotational resistance for the mounting assembly 200. When the nut 128 isactivated to clamp a photovoltaic module between the upper bracket 230and the lower bracket 210, the upper bracket 230 will try to rotatecounterclockwise in the views shown in FIGS. 16A and 16B (reducing theoffset in the lateral dimension between the fourth leg 236 and the hole234 should reduce the amount of the force that attempts to rotate theupper bracket 230 in the manner). Having the second leg 220 of the lowerbracket 210 be positioned inside the fourth leg 236 of the upper bracket230 resists this rotational motion and may stabilize the mountingassembly 200.

The mounting assembly 200 may incorporate a feature to facilitate aforcible engagement between the fourth leg 236 of the upper bracket 230and the second leg 220 of the lower bracket 210. The above-noted offsetof the hole 234 (upper bracket 230) and the hole 218 (lower bracket 210)in the horizontal or lateral dimension (e.g., the stud 114 may not bedisposed orthogonal to the pitch of a roofing surface on which themounting assembly 200 is installed because of this offset) should forcethe fourth leg 236 of the upper bracket 230 into engagement with thesecond leg 220 of the lower bracket 210 as the nut 128 is tightened toincrease the clamping force being exerted by the lower bracket 210 andupper bracket 230 on a photovoltaic module.

FIGS. 17A and 17B illustrate a photovoltaic system 260, where aphotovoltaic module 58 is engaged by the above-described mountingassembly 200, for instance the frame 62 of the module 58. Generally, alower or bottom surface 63 of a photovoltaic module 58 is positioned onthe upper surface 170 of the mounting plate 110.′ The free end 214 ofthe first leg 212 (of the lower bracket 210) may be positioned against aside surface 64 of this module 58. The underside 249 of the head 246 forthe upper bracket 230 is positioned against an upper surface 65 of thephotovoltaic module 58. The stud 114 is threaded into the mountingdevice 74 to clamp the lower bracket 210 to the mounting device 74. Thenut 128 is threaded onto the stud 114 to clamp an edge section of thephotovoltaic module 58 between the upper bracket 230 and the lowerbracket 210.

The foregoing description of the present invention has been presentedfor purposes of illustration and description. Furthermore, thedescription is not intended to limit the invention to the form disclosedherein. Consequently, variations and modifications commensurate with theabove teachings, and skill and knowledge of the relevant art, are withinthe scope of the present invention. The embodiments describedhereinabove are further intended to explain best modes known ofpracticing the invention and to enable others skilled in the art toutilize the invention in such, or other embodiments and with variousmodifications required by the particular application(s) or use(s) of thepresent invention. It is intended that the appended claims be construedto include alternative embodiments to the extent permitted by the priorart.

1-25. (canceled)
 26. A photovoltaic module mounting assembly,comprising: a lower bracket comprising first and second legs, whereinsaid first leg extends in a first dimension, and wherein said second legextends away from said first leg in a second dimension; and an upperbracket comprising third and fourth legs, wherein said third leg of saidupper bracket and said first leg of said lower bracket are spaced fromone another in said second dimension, and wherein said fourth leg ofsaid upper bracket extends away from said third leg of said upperbracket and engages said second leg of said lower bracket; a threadedclamp fastener that extends through said third leg of said upperbracket, through an open space between said third leg of said upperbracket and said first leg of said lower bracket, and through said firstleg of said lower bracket, wherein said second leg of said lower bracketis located between said threaded clamp fastener and said fourth leg ofsaid upper bracket in said first dimension, wherein a first matingsurface of said second leg of said lower bracket comprises a pluralityof spaced teeth and projects toward said fourth leg of said upperbracket, wherein a second mating surface of said fourth leg of saidupper bracket comprises a plurality of spaced teeth and projects towardsaid second leg of said lower bracket, and wherein said first and secondmating surfaces are disposed in interlocking relation to restrictrelative motion between said upper bracket and said lower bracket insaid second dimension; a first configuration where: 1) said third leg ofsaid upper bracket and said first leg of said lower bracket are spacedby a first distance; and 2) said first and second mating surfaces aredisposed in a first degree of said interlocking relation to restrictrelative motion between said upper bracket and said lower bracket insaid second dimension; and a second configuration where: 1) said thirdleg of said upper bracket and said first leg of said lower bracket arespaced by a second distance that is greater than said first distance;and 2) said first and second mating surfaces are disposed in a seconddegree of said interlocking relation to restrict relative motion betweensaid upper bracket and said lower bracket in said second dimension,wherein said first degree of said interlocking relation for said firstconfiguration is greater than said second degree of said interlockingrelation for said second configuration.
 27. The mounting assembly ofclaim 26, wherein an included angle between said first and second legsof said lower bracket is about 90°.
 28. The mounting assembly of claim26, wherein said first leg of said lower bracket and said third leg ofsaid upper bracket are at least substantially parallel to one another.29. The mounting assembly of claim 26, wherein lower bracket said lowerbracket and said upper bracket collectively define a single, continuouspocket for receiving an edge portion of a photovoltaic module.
 30. Themounting assembly of claim 29, wherein a height of said pocket isadjustable by changing a position of said upper bracket relative to saidlower bracket which changes a spacing between said first leg and saidthird leg in said second dimension, wherein changing said height of saidpocket changes an amount of an interlocking interface between said firstand second mating surfaces that restricts relative motion between saidupper bracket and said lower bracket in said second dimension.
 31. Themounting assembly of claim 26, wherein a length dimension of each ofsaid lower bracket and said upper bracket extends along an edge portionof a photovoltaic module when engaged by said mounting assembly, andwherein said lower bracket has a larger said length dimension than saidupper bracket.
 32. The mounting assembly of claim 26, wherein said freeend of said first leg of said lower bracket comprises a raised lip thatextends in a direction of an overlying portion of said upper bracket.33. The mounting assembly of claim 26, wherein said free end of saidfirst leg of said lower bracket engages a side surface of a photovoltaicmodule when a bottom surface of the photovoltaic module is positioned onsaid mounting plate.
 34. The mounting assembly of claim 26, wherein saidlower bracket and said upper bracket collectively define a single,continuous pocket for receiving an edge portion of a photovoltaicmodule, wherein said threaded clamp fastener extends through said pocketand is the only structure of said mounting assembly that is locatedwithin said pocket.
 35. The mounting assembly of claim 26, wherein anincluded angle between said third and fourth legs of said upper bracketis about 90°.
 36. The mounting assembly of claim 26, wherein said upperbracket further comprises a head that offset from said third leg of saidupper bracket in said second dimension.
 37. The mounting assembly ofclaim 36, wherein said head is disposed at a higher elevation than saidthird leg of said upper bracket.
 38. The mounting assembly of claim 36,wherein a free end of said head and said free end of said first leg ofsaid lower bracket are offset in said first dimension.
 39. The mountingassembly of claim 36, wherein a free end of said head is positionedfurther from said threaded clamp fastener in said first dimension thansaid free end of said first leg of said lower bracket.
 40. The mountingassembly of claim 36, wherein a transition section extends between saidthird leg of said upper bracket and said head, wherein said transitionsection of said upper bracket and said free end of said first leg ofsaid lower bracket are at least generally aligned in said seconddimension.
 41. The mounting assembly of claim 26, wherein a singlecontinuous open space extends from said second leg of said lower bracketin said second dimension in a direction that is away from said fourthleg of said upper bracket.
 42. The mounting assembly of claim 36,further comprising: a first nut mounted on said threaded clamp fastenerand engaged with said third leg of said upper bracket, wherein saidfirst nut is positioned outside of a space between said lower bracketand said upper bracket; and a second nut mounted on said threaded clampfastener and engaged with said first leg of said lower bracket, whereinsaid second nut is positioned within said space between said lowerbracket and said upper bracket.